SHG-A* Absolute, SHG-TC, SHG-TS & SHG-VS Linear Encoders

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1 N NEWLL MESUREMENT SYSTEMS LTD SHG* bsolute, SHGTC, SHGTS & SHGVS Linear Encoders Installation Manual

2 CONTENTS 1.0 Technical Specification Bracketry Preparation Warnings Encoder ssembly Mounting The Reader Head Mounting The Scale Double End Mounting Single End Mounting Scales in Excess of 2.5 Meters Fitting The Scale Guard Cable Routing Final Check...10 ppendix Scale Bracket Mounting Options...12 ppendix B Dimensional Drawing

3 1.0 INTRODUCTION This manual will provide connection and mounting instructions for Newall's bsolute, Digital and Distance Coded linear encoders. It is important that you read and understand this manual prior to commencing the hardware installation. Electronic specifications can be found in the corresponding integration manual. If you have any questions relating to this manual or installation contact Newall or your local authorised Newall representative. 1.1 Bracketry Due to the variety of machine types and applications, it may be necessary to design, make and fit custom brackets for the linear encoder assembly. If custom brackets are needed, make certain they are rigid enough not to allow any flexing or distorting while the machine is in operation. Newall offers a variety of bracket kits to aid in the installation. Contact Newall or your local authorised representative for details. 1.2 Preparation Important For SHGTC and SHG* encoders, the reader head and scale are a matched set. It is very important that the serial number of the reader head matches the serial number etched on the scale tube. Prior to beginning the installation the machine should be studied to determine where the linear encoder(s) will be fitted. In order to reduce erroneous readings caused by machine wear, it is recommended that the scale be fitted as close to the machine lead screw or axial drive shaft as possible. The actual overall scale length is approximately 258mm (10.1") longer than the stated scale travel on these SHG encoders (e.g. if SHG travel length is 40", the overall length of the scale will be 50.1"). For SHGTS and SHGVS outboard mounting of the scale support brackets will add approximately 20mm (3/4") to the effective scale travel (Refer to ppendix ). For a more compact installation, scale travels of 300mm (12") or less may be fitted by supporting one end of the scale only by use of a single end mounting block (Refer to Figure 6.4 and 6.10). The moving member of the linear encoder assembly can be either the reader head or the scale. Cable routing from the reader head should be examined (See Section 8). Each reader head is provided with either a 3.5 meter (11.5') or 7 meter (22') cable. Extension cables are available in 1 meter (3'), 2 meter (6.5'), 3.5 meter (11.5'), 5 meter (16.5') and 10 meter (32') lengths. Contact Newall or your local authorised representative for details. 1.3 Warnings If for any reason the machine axis travel is greater than the actual scale travel, it is recommended that mechanical stops are fitted to the machine to avoid damage caused by over travel. Newall will not accept responsibility for scale and reader head damage caused by machine over travel. Both the reader head and the scale are precision made components and it is important that they are handled with care. By design, the linear encoders can withstand the rigors of the harsh workshop environment. However, permanent damage can occur through bending or severe impact. It is important that the scale be kept at least 13mm (0.5") away from any magnetic bases on indicators or magnetic chucks. 3

4 2.0 ENCODER SSEMBLY Less than 2.5m (100 ) Item Description Item Description 1 Reader Head 2 Scale 3 Scale Support Link 4 Scale nchor Pin 5 Support Pillar Short 6 Support Pillar Long 7 Scale Cover 8 M5 Nut 9 M8 x Socket Button Head 3.0 MOUNTING THE REDER HED Mount the reader head together with its bracket(s) to the machine and secure the assembly parallel with axis travel to within +/0.05mm (0.002"), (Refer to Figure 3.1). Figure 3.1 lignment of the reader head Final adjustments can be carried out by use of laminated shims, which are included with each transducer assembly. Each layer of shim is equivalent to 0.05mm (0.002"). 4

5 4.0 MOUNTING THE SCLE 4.1 Double End Mounting Note: Refer to section 4.3 for mounting scales in excess of 2.5 metres. Each end of the scale is different and can be identified by the calibration adjustment end and the fixed end. NOTES: () (B) (C) Figure 4.1 Scale Erroneous readings will occur if the reader head is allowed to travel beyond the effective travel limits (Refer to Figure 4.1). The preload on the balls are factory set via the set screw at the calibration adjustment end. Caution: Do not tamper with or adjust the set screw as this will alter the calibration and accuracy specification of the scale and void the warranty (Refer to Figure 4.1). When mounting scales in the vertical plane, the calibration adjustment end should be positioned at the top. Once the reader head is secured and correctly aligned, the scale support brackets can now be fitted. The scale support brackets consist of the support pin, the support link and the pillar(s). Traverse the machine to its maximum position toward the noncable entry side of the reader head. Maximum position means all available travel, including hand winding past any electrical limits or trip dogs. Carefully slide the scale or setup tube through the reader head, allowing for a sufficient amount of scale to project from the reader head in order to fit the scale support brackets. Note: If the scale travel is more then 60" it is recommended that a setup tube is used for alignment to avoid accidental damage to the actual scale tube. ssemble the scale support link to the scale support pin leaving approximately 3mm (1/8") gap between the bottom of the pin shoulder and the top of the link. Slide the link/pin assembly onto the scale to approximately 5mm (0.2") away from the end of the reader head. Transfer punch through the support link and into the machine casting. It is important that the support link is kept square to its mounting surface at all times. Remove the link/pin assembly and the scale from the reader head. Drill and tap M8 x 18mm deep (US 5/16 18 x 3/4" deep) into the machine casting as marked by the transfer punch. Fit the pillar(s) to the machine casting by using one of the methods shown in Figure 4.3. The pillar should fit square and flush to the machine surface. 5

6 maximum of two support pillars may be screwed together to allow for sufficient adjustment of the scale. If two pillars are insufficient to enable the scale to be mounted, then additional brackets will be necessary. These brackets must be sufficiently rigid to eliminate any axial movement of the scale. Loosely fit the support link/pin assembly onto the pillar and pass the scale through the reader head and into the support pin. While gently sliding the scale forward and back 25 50mm (1 2") through the support pin, carefully tighten the hex screws on the support link, ensuring that the scale slides smoothly through the reader head and into the support pin. If any interference is detected then fully loosen the hex screws on the support link and repeat this step. Note: Do not force the scale through the Support Pin. IMPORTNT WRNING: THE CENTER LINE BORE OF THE REDER HED MUST BE IN DIRECT LIGNMENT WITH THE CENTER LINE BORE OF THE SUPPORT PIN. PERMNENT DMGE TO SCLE ND/OR ERRONEOUS REDINGS WILL OCCUR IF THIS WRNING IS NOT FOLLOWED (REFER TO FIGURE 4.2). Figure 4.2 Reader head and bracket alignment Remove the scale from the reader head and traverse the machine to its full extent in the opposite direction. Full extent means hand winding past electrical limits. ssemble the scale support link to the scale support pin leaving approximately 3mm (1/8") gap between the bottom of the pin shoulder and the top of the link. Slide the link/pin assembly onto the scale making certain that there is sufficient clearance between the reader head and the support link to prevent damage to the reader head cable. Do not secure the support pin to the scale at this time. Transfer punch through the support link and into the machine casting. It is important that the support link be kept square to its mounting surface at all times. 6

7 Remove the link/pin assembly and the scale from the reader head. Drill and tap M8 x 18mm deep (US 5/16" 18 x 3/4" deep) into the machine casting as marked by the transfer punch. Fit the pillar(s) to the machine casting by using one of the methods shown in Figure 4.3. The pillar shoulder fit square and flush to the machine surface. Figure 4.3 Support pillars maximum of two support pillars may be screwed together to allow for sufficient adjustment of the scale. If two pillars are insufficient to enable the scale to be mounted, then additional brackets will be necessary. These brackets must be sufficiently rigid to eliminate any axial or radial movement of the scale. Loosely fit the support link/pin assembly onto the pillar and pass the scale through the reader head and into the support pin. While gently sliding the scale forward and back 25 50mm (1 2") through the support pin, carefully tighten the hex screws on the support link, ensuring that the scale slides smoothly through the reader head and into the support pin. If any interference is detected then fully loosen the hex screws on the support link and repeat this step. Carefully slide the scale through the support pin, through the reader head and into the opposite support pin. FULLY TIGHTEN THE SUPPORT PIN HEX SCREW T THE FIXED END OF THE SCLE, BUT ONLY SNUG UP THE HEX SCREW ON SUPPORT PIN T THE CLIBRTION DJUSTMENT END. 4.2 Single End Mounting Note: The maximum total length of the scale must not exceed 610mm (24") when using a single end mounting kit. The single end mounting kit is sold separately, UK part number , US part number For SHG* and SHGTC remove the nylon pan head screw from the end of the scale to access the tapped hole. For SHGTS and SHGVS, remove the red end cap from the end of the scale to access the tapped hole. fter the reader head has been installed, slide the scale through the reader head and insert the end of the scale into the single end mounting block (Refer to Figure 4.4). Once the position for the single end mounting block has been determined mark the machine casting using the slot in the mounting block as the guide. Drill and tap M6 x 12mm deep (US 1/4 20 x 1/2"). Fit the mounting block using the M6 (US 1/4 20") socket head cap screw and washer. Check the alignment by gently sliding the scale through the head and in and out of the mounting block. djustments may be carried out by adjusting the M5 jacking screws. When the alignment is complete secure the scale by inserting the M5 screw and washer through the mounting block and into the calibration adjustment end of the scale. 7

8 58.00 SINGLE END MOUNTING BLOCK FIXING SLOT FOR M6 SCREW JCKING SCREWS M5 Figure 4.4 Single end mounting 4.3 Scales in Excess of 2.5 Meters Traverse the machine to fullest extent of travel including hand winding past any electrical limits or trip dogs. Insert the set up tube into the reader head, allowing for a sufficient amount of scale to project from the reader head in order to fit the scale mounting brackets. ssemble the angle bracket to the scale clamp (Refer to Figure 4.5). The jack plate is included in each bracket kit and will only be required if the machine mounting face is not a machined surface. Slide the assembly onto the scale, allowing approximately 10mm clearance from the end of the reader head. Mark the position of the jack plate (if required) or the angle support bracket. Drill and tap the necessary fixing holes and assemble the bracket to the machine. Remove the blank tube and the bracket assembly from the reader head. Drill and tap M8 x 18mm (US 5/16 18 x 3/4") fixing holes. Fit the jack plate (if required) and secure to the machine. ssemble the scale clamp and the angle bracket to the jack plate but do not secure. Traverse the reader head as near to the bracket assembly as possible. Slide the setup tube through the reader head into the scale clamp. djust the brackets into position and carefully tighten the screws. Check that the setup tube slides through the reader head and into the scale clamp smoothly without any fouling or interruption. Remove the setup tube and traverse the machine to the full extent in the opposite direction. Remember the full extent is the absolute maximum travel up to the mechanical dead stops. Check the overall length of the actual scale and measure from the outside edge of the scale clamp already fitted to the machine and mark the position of the scale on to the machine. Slide the setup tube into the reader head, assemble the remaining scale bracket assembly including the jacking plate (if required) and slide onto the tube. Set the outside edge of the scale clamp level with the mark that indicates the overall length of the scale and mark the fixing position for the bracket assembly. 8

9 Figure 4.5 Long scale support bracket assembly For scales which are mounted in the horizontal position, spring loaded scale supports are included and should be positioned according to Table 1. Once the locations for the supports have been determined, the reader head should be positioned in the location where the first support is to be fitted. ssemble the support unit, including the jack plate if required. Mark the position for the fixing screws, drill and tap (M8 for the jack plate or M6 for the angle bracket). Ensure that the angle bracket has sufficient movement utilising the two slots to allow for adjustment in the vertical plane. It is important that the top face of the angle bracket is set to 58.5mm (2.3") from the bottom machined face on the reader head. Figure 4.6 Long scale mounting and support details 9

Length 2500mm 3000mm 3500mm 4000mm 4500mm 5000mm 5500mm 6000mm 6500mm 7000mm 7500mm 8000mm 8500mm 9000mm 9500mm 10000mm 10500mm 11000mm No.

10 Length 2500mm 3000mm 3500mm 4000mm 4500mm 5000mm 5500mm 6000mm 6500mm 7000mm 7500mm 8000mm 8500mm 9000mm 9500mm 10000mm 10500mm 11000mm No. of Scale Supports FROM FIXING BRCKET Left Side () Right Side (B) 850mm 850mm 1100mm 1100mm 1350mm 1350mm 1125mm 1125mm 1250mm 1250mm 1350mm 1350mm 1300mm 1300mm 1400mm 1400mm 1600mm 1600mm 1410mm 1410mm 1580mm 1580mm 1420mm & 2840mm 1420mm & 2840mm & 3000mm & 3000mm 1570mm & 3140mm 1570mm & 3140mm Table 1 Mid Position of Travel (B) 2250mm 2500mm 2750mm 3000mm 4250mm 4500mm 4750mm 5.0 FITTING THE SCLE GURD Left Side Position of Travel (C) 650mm 700mm 750mm 800mm 1410mm 1580mm 710mm 750mm 785mm Right Side Position of Travel (C) 650mm 700mm 750mm 800mm 1410mm 1580mm 710mm 750mm 785mm Each encoder includes a protective guard. This aluminium guard is intended to protect the scale from impact damage. The guard can be attached to the machine casting or by means of the scale support pillars (Refer to Figure 5.1). To fit the guard to the support pillars, measure and mark off the distance between the center of each pillar. For SHG, drill two 8.5mm (3/8") holes at either end of the guard. The guard can be attached to the pillars by using the button head screws provided. fter the guard is attached, move the machine axis to both extents of its travel ensuring that the guard does not interfere with or rub against the reader head. Figure 5.1 Fitting the scale guard (example shown using a Spherosyn scale) 10

11 6.0 CBLE ROUTING The most important and the most over looked aspect of fitting the linear encoder is proper cable routing. Dangling and loose cables can be snagged or broken causing irreparable damage. Care should be taken in order to ensure that the cables are secured to the machine and that cable loops do not interfere with any part of the machine or the linear encoder movements. P clips and thread forming screws are provided to route the cables from the reader head. Note: The armoured cable is an integral part of the reader head. If the cable becomes damaged, then it would have to be replaced complete with the reader head. If extension cables are used, do not allow the plug and socket junction to lie in the swarf tray or in the direct flow of coolant or oil. Optional IP67 rated submergible connectors are available if required. In order to avoid problems associated with electrical noise and interference, do not allow the cables to lie across electrical motors, fuse boxes or electrical pumps. 7.0 FINL CHECK Prior to putting the linear encoder into operation, slowly traverse the machine axis to both extents of its travel checking at all times that the cables are secure and that machine over travel cannot occur. Newall will not accept responsibility for linear encoder malfunction caused by over travel or damaged cables. 11

12 ppendix SCLE BRCKET MOUNTING OPTIONS Outboard scale support mounting Scale supports inverted 12

13 ppendix B DIMENSIONL DRWING 58 (2.28 ) 28 (1.1 ) (H) (H) C C P3¹ (E) P4¹ (H) C 25.4 (1 ) FXG SLOT FOR M6 (¼ UNC) SCREW 15.4 (0.6 ) 25.4 (1 ) P3 P1 P2 P4 OPTIONL SINGLE END SCLE MOUTING KIT R2.8/360 Rotational adjustment Scale end reference groove SHG & SHGTC only Serial No. & Zero Point SHGTS & SHGVS do not have zero point OVERLL SCLE LENGTH MINIMUM = TRVEL LENGTH (10.2 ) 6.5 (0.26 ) 131 (5.16 ) 118 (4.65 ) 2 (0.08 ) djustment (H) 28 (1.1 ) / 30 (1.2 ) lignment mark for scale P1¹ P1 (G) P2 P2¹ R17/360 Rotational adjustment 38 (1.5 ) djustment SCLE MOUNTING BRCKET DJUSTMENT Short pillar 26 (1 ) Long pillar (38 (1.5 ) fix both together for extended length of 64 (2.5 ) 22.5 (0.89 ) 22.5 (0.89 ) Min. 16 (0.6 ) Max. 54 (2.1 ) (H) 35.0 (1.38 ) 53 (2.1 ) Dimensions mm (in ) Encoder head mounting points 2off for M5 (1024UNC) cap head screws (clearance holes through) B Encoder head mounting points 2off for M5 screws (thread depth 12) C Scale pillar mounting studs M8 x 15 (5/1618 UNC US) (use spacer washer as required) D Machine guideway E/F Encoder head mounting faces G Indicating prallel alignment required between encoder head and axis travel H Scale end mounting points to machine bed P Installation alignment points C Pillar end mounting points M8 (5/1618UNC) x 18 deep C Bore ø8.4 x 5 deep 20.0 (0.79 ) (1.53 ) 53.5 (2.11 ) 6.5 (0.26 ) B P1¹ 11 (0.43 ) 28.5 (1.12 ) (F) 118 (4.65 ) TRICOLOUR LED rmoured cable ø8.5 (0.33 ) (min. internal bend radius 30 (1.2 ) Nonarmoued cable ø5.6 (0.22 ) P2¹ B Mountings ø5.5 THR O & C BORE ø9.0 x 6 DEEP each side of housing to accept M5 (1024UNC) cap head screws ø15.2 (0.6 ) C (H) NOTE: LINER ENCODERS OVER 2540 (100 ) OF TRVEL UTILISE DIFFERENT MOUNTING BRCKETS 13

14 6.5 (0.26 ) 131 (5.16 ) 118 (4.65 ) Spring loaded centre support (C) 50 (2 ) 0.50 (0.02 ) Serial No. and Zero Point (Serial No. only on S.P) P (0.79 ) (1.53 ) 53.5 (2.11 ) // // P1 (G) P2 lignment mark for scale (F) D D P2 1 TRICOLOUR LED 9.5 (0.38 ) 50 (2 ) 10 (0.4 ) 72 (2.8 ) Heavy duty scale bracket (H) 9.5 (0.38 ) 50 (2 ) 38 (1.5 ) (H) Heavy duty scale bracket (C) OVERLL SCLE LENGTH MINIMUM = TRVEL LENGTH (10.2 ) P3 1 P4 1 (E) P1 P2 P3 P4 // // D D (G) 9.5 (0.38 ) 70 (2.75 ) 25.4 (1 ) 9.5 (0.38 ) 50 (2 ) Encoder head mounting points 2off for M5 (1024UNC cap head screws (clearance holes through) B Encoder head mounting points 2off for M5 screws (thread depth 12) C Sping loaded centre support D Machine Guideway E/F Encoder head mounting faces G Indicating parallel alignment required between encoder head and axis travel H Scale end mounting points to machine bed P Installation alignment points Spring loaded centre support 6.5 (0.26 ) P (0.43 ) 28.5 (1.12 ) B 118 (4.65 ) P2 1 B ø15.2 (0.6 ) Mounting ø5.5 THR O & C BORE ø9.0 X 6 DEEP each side of housing to accept m5 (1024UNC) cap head screws SPRING LODED CENTRE SUPPORTS RE INTENDED FOR USE WHERE THE REDER HED IS MOVING ND THE SCLE TUBE IS STTIONRY (H) rmoured cable ø8.5 (0.33 _ (min. internal bend radius 30 (1.2 ) Nonarmoured cable ø5.6 (0.22 ) (H) 1 ppendix B DIMENSIONL DRWING REFER TO DRWING FOR RECOMMENDED NUMBER ND POSITIONL DETILS OF SPRING LODED CENTRE SUPPORTS 14

15 Notes 15

16 NEWLL MESUREMENT SYSTEMS LTD HED OFFICE Ltd. Technology Gateway, Cornwall Road South Wigston Leicester LE18 4XH United Kingdom Telephone: +44 (0) Facsimile: +44 (0) Web: Newall Electronics, Inc Dividend Drive Columbus, OH Telephone: Toll Free: Facsimile: Web: UK. June 2007

bsolute Encoder Installation lignment For the correct operation of all Newall bsolute Linear Encoders it is required that the alignment of the readerhead and scale is correctly set.

17 bsolute Encoder Installation N IMPORTNT For SHG* and SHGTC encoders, the reader head and scale are a matched set. It is very important that the serial number of the reader head matched the serial number etched on the scale tube. bsolute Encoder Installation lignment For the correct operation of all Newall bsolute Linear Encoders it is required that the alignment of the readerhead and scale is correctly set. The following procedure must be used to ensure correct encoder installation and operation. Zero Point Marker bsolute Encoders take their zero position from a fixed datum on the encoder scale. For guidance the scale is marked with an arrow and a line at the position where this zero datum position is defined. This point is 55mm in from the end of the scale. Encoder Serial Number Encoder Zero Point Installation Install the scale and reader head hardware as described in the Spherosyn bsolute, Distance Coded, and Digital SP Encoder Hardware Installation Manual supplied. It is important to ensure that the scale and reader head are rotationally aligned before operation. There is an arrow etched into the tube that needs to be aligned with the notch in the reader head. Once aligned the scale brackets are tightened as detailed in the installation manual. pply power to the readerhead. The Signal LED on the front of the readerhead will go RED and then GREEN as it establishes position and performs its selfdiagnostics. lign arrow with notch Move the readerhead along the full length of travel from the scale (taking care not enter the unusable sections at either end of the scale). Cycle power periodically as you traverse the reader head along the scale. The readerhead LED should go RED then GREEN each time the power is turned on. If the LED stays RED then there is misalignment between the reader head and scale. If this occurs loosen the scale brackets and rotate the scale approximately 23 degrees. Tighten the scale brackets as described in the installation manual and repeat the process until the signal LED remains GREEN for the full period of travel. Once the LED has turned RED, the only way to get the GREEN LED is to cycle power while the encoder is properly aligned. Ltd, Technology Gateway, Cornwall Road, South Wigston, Leicester, LE18 4XH, UK Tel: +44 (0) Fax: +44 (0) sales@newall.co.uk Web: www,newall.co.uk

SHG-A* Absolute, SHG-TC, SHG-TS & SHG-VS Linear Encoders

SHG-A* Absolute, SHG-TC, SHG-TS & SHG-VS Linear Encoders N NEWALL MEASUREMENT SYSTEMS LTD SHGA* Absolute, SHGTC, SHGTS & SHGVS Linear Encoders Installation Manual THIS MANUAL SHOULD BE USED IN CONJUNCTION WITH WITH THE CORRESPONDING PROTOCOL DOCUMENT Contents